Tension regulator for actuation elements, and related remotely actuated instruments, systems, and methods

ABSTRACT

A device to regulate tension of an actuation element for actuating movement of a surgical instrument includes an elastically deformable body configured to be coupled to the actuation element. The deformable body is configured to elastically deform in response to a state of slack occurring in the actuation element. As slack occurs in the actuation element, the deformable body is configured to divert a path of the actuation element to accommodate the slack so the path of the actuation element differs from an axis the actuation element follows prior to the actuation element developing slack. A force transmission mechanism for a teleoperated surgical instrument includes a chassis, an actuation input mechanism, an actuation element, and a tension regulator coupled to the actuation element to compensate for slack of the actuation element.

RELATED APPLICATIONS

This patent application claims priority to and the benefit of the filingdate of U.S. Provisional Patent Application 62/151,138, entitled“TENSION REGULATOR FOR ACTUATION ELEMENTS, AND RELATED REMOTELY ACTUATEDINSTRUMENTS, SYSTEMS, AND METHODS” filed Apr. 22, 2015, which isincorporated by reference herein in its entirety.

TECHNICAL FIELD

Aspects of the present disclosure relate to regulate tension inactuation elements, for example, via one or more devices used in a forcetransmission mechanism including such actuation elements. In particular,aspects of the present disclosure relate to surgical instruments thatare actuatable through a force transmission mechanism including one ormore such tension regulating mechanisms.

INTRODUCTION

Benefits of minimally invasive surgery are well known, and they includeless patient trauma, less blood loss, and faster recovery times whencompared to traditional, open incision surgery. In addition, the use ofteleoperated surgical systems (e.g., robotic systems that providetelepresence), such as the da Vinci® Surgical System manufactured byIntuitive Surgical, Inc. of Sunnyvale, Calif. is known. Suchteleoperated surgical systems may allow a surgeon to operate withintuitive control and with precision.

To perform actions directed by a surgeon, a surgical instrument may usea force transmission mechanism that receives drive inputs and transmitsassociated forces via actuation elements from a proximal end of thesurgical instrument, along its shaft, to a distal portion of thesurgical instrument. In some cases, the actuation elements includetension members, such as cables, wires, or the like. Slack that maydevelop in such actuation elements can affect the transmission of forcealong such actuation elements. In addition, slack can lead tomisalignment and/or derailment of actuation elements, such as, forexample, at capstans or pulleys. It is desirable, therefore, to provideways to manage slack so as to minimize or prevent misalignment orderailment of actuation elements and/or to provide responsiveness offorce transmission from the drive input at the force transmissionmechanism to the ultimate actuation of a distal end portion of thesurgical instrument.

SUMMARY

Exemplary embodiments of the present disclosure may solve one or more ofthe above-mentioned problems and/or may demonstrate one or more of theabove-mentioned desirable features. Other features and/or advantages maybecome apparent from the description that follows.

In accordance with at least one exemplary embodiment, a device toregulate tension of an actuation element for actuating movement of asurgical instrument comprises an elastically deformable body configuredto be coupled to the actuation element. The deformable body isconfigured to elastically deform in response to a state of slackoccurring in the actuation element. As slack occurs in the actuationelement, the deformable body is configured to divert a path of theactuation element to accommodate the slack so the path of the actuationelement differs from an axis the actuation element follows prior to theactuation element developing slack.

In accordance with at least one exemplary embodiment, a forcetransmission mechanism for a teleoperated surgical instrument comprisesa chassis, an actuation input mechanism mounted to the chassis, anactuation element, and a tension regulator. The actuation inputmechanism is configured to receive forces from an actuation interfaceassembly of a teleoperated surgical system. The actuation element isconfigured to transmit force sufficient to actuate an end effector ofthe surgical instrument. The tension regulator is coupled to theactuation element to compensate for slack of the actuation element. Asslack occurs in the actuation element, the tension regulator isconfigured to divert a path of the actuation element to accommodate theslack so the path of the actuation element differs from an axis theactuation element follows prior to the actuation element developingslack.

In accordance with at least one exemplary embodiment, a method ofcompensating for slack in an actuation element of a surgical instrumentcomprises coupling a tension regulator comprising an elasticallydeformable body to the actuation element, and compensating for slackdeveloping in the actuation element by diverting a path of the actuationelement so the path of the actuation element differs from an axis theactuation element follows prior to the actuation element developingslack.

Additional objects, features, and/or advantages will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the present disclosureand/or claims. At least some of these objects and advantages may berealized and attained by the elements and combinations particularlypointed out in the appended claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the claims; rather the claims should beentitled to their full breadth of scope, including equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be understood from the following detaileddescription, either alone or together with the accompanying drawings.The drawings are included to provide a further understanding of thepresent disclosure, and are incorporated in and constitute a part ofthis specification. The drawings illustrate one or more exemplaryembodiments of the present teachings and together with the descriptionserve to explain certain principles and operation. In the drawings,

FIG. 1 shows a patient side cart of a teleoperated surgical system,according to an exemplary embodiment.

FIG. 2 shows a diagrammatic perspective view of a surgical instrument,according to an exemplary embodiment.

FIG. 3 is a perspective view of an interior portion and chassis of aforce transmission mechanism, according to an exemplary embodiment.

FIG. 4 is a partial, perspective view of actuation elements and tensionregulators of FIG. 3.

FIG. 5 is a partial view of actuation elements each including a tensionregulator, according to an exemplary embodiment.

FIG. 6 is a plan view of a tension regulator, according to an exemplaryembodiment.

FIG. 7 is a side view taken from the view 7-7 in FIG. 6.

FIG. 8 depicts the tension regulator of FIG. 6 coupled to an actuationelement in a taut state, according to an exemplary embodiment.

FIG. 9 depicts the tension regulator and actuation element of FIG. 8 ina slack state.

FIG. 10 depicts the tension regulator and actuation element of FIG. 9another slack state.

FIG. 11 depicts a tension regulator coupled to an actuation element in aslack state, according to another exemplary embodiment.

FIG. 12 depicts a tension regulator, according to yet another exemplaryembodiment.

FIG. 13 depicts a tension regulator coupled to a force transmissionelement in a taut state, according to another exemplary embodiment.

FIG. 14 depicts the tension regulator and actuation element of FIG. 13in a slack state.

FIG. 15 depicts a tension regulator coupled to an actuation element in aslack state, according to another exemplary embodiment.

FIG. 16 depicts a tension regulator coupled to two actuation elements,according to an exemplary embodiment.

FIG. 17 depicts a tension regulator mounted to a force transmissionmechanism and coupled to an actuation element, according to an exemplaryembodiment.

DETAILED DESCRIPTION

This description and the accompanying drawings that illustrate exemplaryembodiments should not be taken as limiting. Various mechanical,compositional, structural, electrical, and operational changes may bemade without departing from the scope of this description and claims,including equivalents. In some instances, well-known structures andtechniques have not been shown or described in detail so as not toobscure the disclosure. Like numbers in two or more figures representthe same or similar elements. Furthermore, elements and their associatedfeatures that are described in detail with reference to one embodimentmay, whenever practical, be included in other embodiments in which theyare not specifically shown or described. For example, if an element isdescribed in detail with reference to one embodiment and is notdescribed with reference to a second embodiment, the element maynevertheless be claimed as included in the second embodiment.

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing quantities, percentages, orproportions, and other numerical values used in the specification andclaims, are to be understood as being modified in all instances by theterm “about,” to the extent they are not already so modified.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the following specification and attached claims areapproximations that may vary depending upon the desired propertiessought to be obtained. At the very least, and not as an attempt to limitthe application of the doctrine of equivalents to the scope of theclaims, each numerical parameter should at least be construed in lightof the number of reported significant digits and by applying ordinaryrounding techniques.

It is noted that, as used in this specification and the appended claims,the singular forms “a,” “an,” and “the,” and any singular use of anyword, include plural referents unless expressly and unequivocallylimited to one referent. As used herein, the term “include” and itsgrammatical variants are intended to be non-limiting, such thatrecitation of items in a list is not to the exclusion of other likeitems that can be substituted or added to the listed items.

Further, this description's terminology is not intended to limit thedisclosure or claims. For example, spatially relative terms—such as“beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, andthe like—may be used to describe one element's or feature's relationshipto another element or feature as illustrated in the figures. Thesespatially relative terms are intended to encompass different positions(i.e., locations) and orientations (i.e., rotational placements) of adevice in use or operation in addition to the position and orientationshown in the figures. For example, if a device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be “above” or “over” the other elements or features.Thus, the exemplary term “below” can encompass both positions andorientations of above and below. A device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

In accordance with various exemplary embodiments, the present disclosurecontemplates force transmission mechanisms that include tensionregulators that compensate for slack in actuation elements. In variousexemplary embodiments, the tension regulators may accommodate for slackin a passive manner. According to an exemplary embodiment, tensionregulators may utilize potential energy to passively compensate forslack. For example, a tension regulator may passively compensate forslack by changing its configuration or shape (e.g., via elasticdeformation) as slack develops. Tension regulators of the variousexemplary embodiments described herein may permit tension in anactuation element to be maintained without automated controls or manualadjustments, thus providing an efficient and robust means of regulatingtension of an actuation element. Therefore, as an actuation elementchanges over time and develops slack, the tension regulator maycompensate for slack and substantially maintain a desired tension inactuation element, as will be discussed below.

According to an exemplary embodiment, an actuation element may follow asubstantially straight path as it extends from a transmission mechanismand into the shaft of a surgical instrument. To transmit forces toeffect motion of different portions of the surgical instrument, anactuation element is generally in a state of tension. As slack occurs inan actuation element, however, in accordance with various exemplaryembodiments, a tension regulator coupled to the actuation element mayaccommodate the slack by diverting a portion of the actuation elementaway from an initial path of the actuation element in its taut state.For example, a tension regulator may form one or more bends in theactuation element such that a longitudinal axis of the actuation elementis not straight at a location at which the tension regulator isdisposed. A tension regulator may, therefore, accommodate slack byacting on the actuation element in the portion where slack occurs andexerting a force to maintain tension in that portion. As an actuationelement loses tautness, a tension regulator coupled to the actuationelement may pull an actuation element along a direction that istransverse (e.g., perpendicular) to an original path (e.g., straightpath) of the portion of the actuation element, according to an exemplaryembodiment. Diverting a portion of the length of the actuation elementas the actuation element develops slack (i.e., loses tension), can serveto reestablish and maintain a tensioned, taut condition of the actuationelement. According to an exemplary embodiment, a tension regulator maybe configured to compensate (e.g., dynamically compensate) for varyingamounts of slack (e.g., up to a maximum compensation amount the tensionregulator is capable of), such as when the slack of an actuation elementincreases over time.

A tension regulator may be coupled to an actuation element along aportion of the actuation element that is disposed within a forcetransmission mechanism of a surgical instrument. In various exemplaryembodiments, a tension regulator may be coupled to the actuation elementsuch that the tension regulator moves with the actuation element whenthe actuation element is actuated according to an exemplary embodiment.In various exemplary embodiments, the tension regulator may beconfigured to float with respect to the force transmission mechanism(e.g., move with the actuation element relative to the forcetransmission mechanism), whereas in other exemplary embodiments, thetension regulator may be fixed to a force transmission mechanism, suchas a chassis of a force transmission mechanism. According to anexemplary embodiment, a tension regulator may be coupled to one or moreof a plurality of actuation elements connected to an actuation inputmechanism. Although tension regulators may be coupled to regulatetension in a single actuation element, a tension regulator may becoupled so as to regulate tension in more than one actuation elementsimultaneously, according to an exemplary embodiment.

Various exemplary embodiments described herein contemplate tensionregulators having a single piece (e.g., monolithic) construction. Forexample, a tension regulator may be a single piece of wire, a singlepiece of sheet metal, a single molded piece, a single band of elasticmaterial, or other single piece constructions familiar to one ofordinary skill in the art. A portion of an actuation element extendingthrough a tension regulator may be continuous length portion of theactuation element, according to an exemplary embodiment. In other words,the tension regulator may take up slack by acting on a portion of alength of the actuation element between ends of the actuation element,as opposed to, for example, acting on an end of the actuation element.

Referring now to FIG. 1, an exemplary embodiment of a patient side cart100 of a teleoperated surgical system is shown. A teleoperated surgicalsystem may further include a surgeon console (not shown) for receivinginput from a user to control instruments mounted at patient side cart100. A teleoperated surgical system also can include an auxiliarycontrol/vision cart (not shown), as described in, for example, U.S. Pub.No. US 2013/0325033, entitled “Multi-Port Surgical Robotic SystemArchitecture” and published on December 5, 2013, and U.S. Pub. No. US2013/0325031, entitled “Redundant Axis and Degree of Freedom forHardware-Constrained Remote Center Robotic Manipulator” and published onDec. 5, 2013, each of which is hereby incorporated by reference in itsentirety. Further, the exemplary embodiments described herein may beused, for example, with a da Vinci® Surgical System, da Vinci® SiSurgical System, Single Site da Vinci® Surgical System, or a da Vinci®Xi Surgical System, available from Intuitive Surgical, Inc.

Patient side cart 100 may include a base 102, a main column 104, and amain boom 106 connected to main column 104. Patient side cart 100 mayalso include a plurality of manipulator arms 110, 111, 112, 113, whichmay each be connected to main boom 106. Manipulator arms 110, 111, 112,113 may each include an instrument mount portion 120 to which aninstrument 130 may be mounted, which is illustrated as being attached tomanipulator arm 110. Portions of manipulator arms 110, 111, 112, 113 maybe manipulated during a surgical procedure according to commandsprovided by a user at the surgeon console. In an exemplary embodiment,signal(s) or input(s) transmitted from a surgeon console may betransmitted to the control/vision cart, which may interpret the input(s)and generate command(s) or output(s) to be transmitted to the patientside cart 100, for example through drive interface devices andultimately to the surgical instrument transmission mechanism, to causemanipulation of an instrument 130 (only one such instrument beingmounted in FIG. 1) and/or portions of manipulator arm 110 to which theinstrument 130 is coupled at the patient side cart 100.

Instrument mount portion 120 may comprise an actuation interfaceassembly 122 and a cannula mount 124, with a shaft 132 of instrument 130extending through cannula mount 124 (and on to a surgery site during asurgical procedure) and a force transmission mechanism 134 of instrument130 connecting with the actuation interface assembly 122, according toan exemplary embodiment. Cannula mount 124 may be configured to hold acannula (not shown in FIG. 1) through which shaft 132 of instrument 130may extend to a surgery site during a surgical procedure. Actuationinterface assembly 122 may contain a variety of drive (e.g., inputdrive) and other mechanisms that are controlled to respond to inputcommands at the surgeon console and transmit forces to the forcetransmission mechanism 134 to actuate instrument 130, as those skilledin the art are familiar with, and thus can be broadly classified as adrive interface device. For instance, the input drives of actuationinterface assembly 122 may directly engage with an interface structures(not shown) of force transmission mechanism 134 and transmit forces toforce transmission mechanism 134, as will be discussed below.

Although the exemplary embodiment of FIG. 1 shows an instrument 130attached to only manipulator arm 110 for ease of illustration, aninstrument may be attached to any and each of manipulator arms 110, 111,112, 113. An instrument 130 may be a surgical instrument with an endeffector or may be an endoscopic imaging instrument or other sensinginstrument utilized during a surgical procedure to provide information,(e.g., visualization, electrophysiological activity, pressure, fluidflow, and/or other sensed data) of a remote surgical site. In theexemplary embodiment of FIG. 1, a surgical instrument with an endeffector or an imaging instrument may be attached to and used with anyof manipulator arms 110, 111, 112, 113. However, the embodimentsdescribed herein are not limited to the exemplary embodiment of thepatient side cart of FIG. 1 and various other teleoperated surgicalsystem configurations, including patient side cart configurations, maybe used with the exemplary embodiments described herein.

Turning to FIG. 2, a schematic side view of an exemplary embodiment of asurgical instrument 200 is shown. For instance, surgical instrument 200may be used as instrument 130 with the patient side cart 100 of theexemplary embodiment of FIG. 1. Surgical instrument 200 may include aforce transmission mechanism 210 (a chassis 211 for which is shown inthe exemplary embodiment of FIG. 2, with a housing being removed fromthe illustration so as reveal components of the force transmissionmechanism 210 within), a shaft 222 connected to force transmissionmechanism 210 at a proximal end 223 of shaft 222, a wrist 230 connectedto a distal end 224 of shaft 222, and an end effector 220 connected towrist 230. Shaft 222 may be flexible or rigid. According to an exemplaryembodiment, shaft 222 may have a diameter ranging from about 3 mm toabout 15 mm. According to another exemplary embodiment, the diameter ofshaft 222 may range, for example, from about 5 mm to about 8 mm. Endeffector 220 may comprise, for example, forceps, a needle driver forsuturing, cutting devices, dissecting devices, clip appliers, and otherend effector configurations for performing various surgical procedures.

Surgical instrument 200 may include one or more members to translateforce between force transmission mechanism 210 and end effector 220and/or between force transmission mechanism 210 and wrist 230. Forexample, actuation elements 242, 244 may connect force transmissionmechanism 210 to end effector 220 to provide actuation forces to endeffector 220, such as by extending through an interior of shaft 222. Byutilizing actuation elements 242, 244, force transmission mechanism 210may actuate end effector 220 to control, for example, a jaw of endeffector 220 (or other moveable part of end effector 220). In anotherexample, actuation elements 242, 244 may be utilized to actuate wrist230 in one or more degrees of freedom (e.g. pitch and/or yaw). Actuationelements 242, 244 may be in the form of tension members, such as whenforce transmission mechanism 210 is a pull-pull mechanism, as describedin U.S. Pat. No. 8,545,515, which is hereby incorporated by reference inits entirety.

Force transmission mechanism 210 may include one or more components toengage with a patient side cart 100 of a teleoperated surgical system totranslate a force provided by patient side cart to surgical instrument200. For example, force transmission mechanism 210 may connect with theactuation interface assembly 122 of the patient side cart 100 of theexemplary embodiment of FIG. 1 so actuation interface assembly 122 maytransmit forces to force transmission mechanism 210 to actuateinstrument 200. According to an exemplary embodiment, force transmissionmechanism 210 may include one or more driven actuation input mechanisms212, 214 that engage (e.g., via a distal end of force transmissionmechanism 210) with a manipulator of a patient side cart, such asactuation interface assembly 122 of patient side cart 100.

According to an exemplary embodiment, actuation input mechanisms 212,214 may interact with a manipulator of a patient side cart, such asactuation interface assembly 122 of patient side cart 100, via a sterileadapter (not shown), as will be described below. One exemplary type ofactuation input mechanism that can be used in force transmissionmechanism 210 is a pull-pull mechanism, exemplary embodiments of whichare described in U.S. Pat. No. 8,545,515, which is hereby incorporatedby reference in its entirety. According to an exemplary embodiment,force transmission mechanism 210 may utilize a pull-pull mechanism,actuation elements 242, 244 may be tension members, and driven actuationinput mechanisms 212, 214 may be capstans that are rotationally drivenby actuation interface assembly 122 to tension actuation elements 242,244 to actuate instrument. Thus, driven actuation input mechanisms 212,214 utilize actuation forces from an actuation interface assembly toactuate instrument 200. Force transmission mechanism 210 may includeother components in addition to or in lieu of capstans to actuatevarious other functionalities of a surgical instrument, as those havingordinary skill in the art are familiar with. Such components include,but art no limited to, gears, clutches, pulleys, linkages, and othermechanisms to convert input force and/or motion into a desired outputforce and/or motion. Further, force transmission mechanism 210 mayinclude other numbers of actuation input mechanisms 212, 214 than shownin the exemplary embodiment of FIG. 2, such as, for example, one, three,four, five, six, seven, eight or more actuation input mechanisms. Forexample, any number of actuation input mechanisms 212, 214 may be used,depending on the nature of a surgical instrument and depending upon thedegrees of operational freedom of such an instrument.

The force transmission mechanism of FIG. 2 provides an accurateconversion of rotational movement to translation movement of anactuation element for a surgical instrument of a teleoperated surgicalsystem. However, actuation elements of a force transmission mechanismcan experience a change in shape. For example, actuation element 242 ofthe exemplary embodiment of FIG. 2, which may be a tension member, maydeform, such as by stretching and increasing in length in proportion toa load delivered. As a result, actuation element 242 may develop slack.Actuation element 244 may move in coordination with actuation element242 if both are coupled to a movement of the wrist 230 or end effector220. With such coordinated movement, actuation element 244 also maydevelop slack. Conversely, actuation element 242 could be in tension,with actuation element 244 having slack. Further, when actuationelements 242, 244 are in a state of slack, the precision of forcetransmission mechanism 210 to actuate instrument 200, such as endeffector 220 or wrist 230, may diminish. For instance, rotation ofdriven actuation input mechanisms 212, 214 may need to be rotated toremove slack from actuation elements 242, 244 in order to place theactuation elements 242, 244 in a taut state in which they can actuateinstrument 200. In addition, driven actuation input mechanisms 212, 214may include a groove (not shown) in which the actuation elements 242,244 normally lie during use of force transmission mechanism 210. Slackin actuation elements 242, 244 could become significant enough thatactuation elements 242, 244 move out of the groove, which can alsoaffect the actuation of instrument 200. Therefore, further improvementscan be made with surgical instrument components to compensate forchanges in actuation elements, such as by using tension regulationdevices that utilize the limited space within a surgical instrument in amore efficient way.

Turning to FIG. 3, an interior portion of a force transmission mechanism310 is shown, according to an exemplary embodiment. Force transmissionmechanism 310 may comprise a chassis 320 and a housing (not illustratedto reveal components of force transmission mechanism 310 within). Forcetransmission mechanism 310 may be used as transmission mechanism 134 ofinstrument 130 of the exemplary embodiment of FIG. 1. According to anexemplary embodiment, force transmission mechanism 310 may compriseother components, such as, for example, a roll gear (not shown) toengage a proximal portion of a shaft (not shown) of an instrument androll the shaft, such as shaft 222 of instrument 200 in the exemplaryembodiment of FIG. 2, flux conduits to deliver flux (e.g., electricalenergy, fluids, suction, light, etc.) to an end effector of aninstrument, and other components familiar to one of ordinary skill inthe art.

Force transmission mechanism 310 may comprise one or more actuationinput mechanisms 330, 332, as shown in the exemplary embodiment of FIG.3. In an exemplary, nonlimiting embodiment, actuation input mechanisms330, 332 may be capstans, as discussed above with regard to actuationinput mechanisms 212, 214 of the exemplary embodiment of FIG. 2,although various other actuation input mechanism configurations may beused without departing from the scope of the present disclosure.Actuation elements may be respectively coupled to driven actuation inputmechanisms 330, 332. For example, actuation elements 340, 342 may becoupled to actuation input mechanism 330 and actuation elements 344, 346may be coupled to actuation input mechanism 332, as shown in theexemplary embodiment of FIG. 3. According to an exemplary embodiment,actuation elements 340, 342, 344, 346 may be tension members, such ascables, as described in U.S. Pat. No. 8,545,515, issued Oct. 1, 2013,which is hereby incorporated by reference in its entirety. According toan exemplary embodiment, a pull-pull mechanism may include two tensionmembers, with one tension member pulled to actuate an end effector orwrist in one direction and the other tension member pulled to actuatethe end effector or wrist in another direction. According to anotherexemplary embodiment, a pull-pull mechanism may include a single tensionelement (e.g., a single tension element wrapped about a capstan or otheractuator), with one portion of the tension element pulled to actuate anend effector or wrist in one direction and another portion of thetension member pulled to actuate the end effector or wrist in anotherdirection. Chassis 320 of force transmission mechanism 310 may furthercomprise a chassis portion 322 that defines an exit aperture 324 intowhich actuation elements 340, 342, 344, 346 extend so actuation elements340, 342, 344, 346 may be routed through a shaft (e.g., shaft 222 inFIG. 2) to a distal portion of an instrument, according to an exemplaryembodiment.

The actuation elements connected to a driven actuation input mechanismmay be formed by a single actuation element, according to an exemplaryembodiment. Thus, actuation elements 340, 342 connected to actuationinput mechanism 330 may be formed by a single actuation element, withactuation elements 340, 342 defined by two potions of the singleactuation element that extend between force transmission mechanism 310and a distal portion of an instrument. For example, actuation elements340, 342 may be portions of a single actuation element (e.g., cable)that loops about actuation input mechanism 330 at one end in forcetransmission mechanism, extends from force transmission mechanism 310through the shaft of an instrument (e.g., shaft 222 in FIG. 2), to adistal portion of an instrument (e.g., wrist 230 or end effector 220 inFIG. 2) to actuate instrument when actuation input mechanism 330 isdriven. Thus, when actuation input mechanism 330 is driven, such as bybeing rotated along the directions indicated by arrows 331 in theexemplary embodiment of FIG. 3, one of the portions of the singleactuation element (e.g., one of actuation elements 340, 342) is paid outfrom actuation input mechanism 330 while the other portion of the singleactuation element (e.g., the other of actuation elements 340, 342) istaken up (e.g., wound upon) actuation input mechanism 330. Actuationelements 344, 346 connected to actuation input mechanism 332 may besimilarly arranged.

According to another exemplary embodiment, actuation elements 340, 342may be two separate actuation elements. For example, a first end of eachof actuation elements 340, 342 may be connected to actuation inputmechanism 330 and a second end of each of actuation elements 340, 342may be connected to a distal portion of an instrument (e.g., wrist 230or end effector 220). Actuation elements 344, 346 connected to actuationinput mechanism 332 may be arranged as two separate actuation elements,according to an exemplary embodiment. Thus, actuation elements (e.g.,actuation elements 340, 342 in FIG. 3) connected to an actuation inputmechanism (e.g., actuation input mechanism 330 in FIG. 3) may be twoportions of a single actuation element or may be defined by twoactuation elements.

According to an exemplary embodiment, tension regulators of the variousexemplary embodiments described herein may be coupled to at least oneactuation element of a force transmission mechanism either before orafter the force transmission mechanism has been assembled. For example,a tension regulator may be coupled to an actuation element after theactuation element has been connected to a wrist or end effector of aninstrument (e.g., 230 or 220 in FIG. 2) and connected to an actuationinput mechanism (e.g., 330 or 332 in FIG. 3). According to anotherexemplary embodiment, a tension regulator may be coupled to an actuationelement and then the actuation element may be connected to a wrist orend effector of an instrument (e.g., 230 or 220 in FIG. 2) and connectedto an actuation input mechanism (e.g., 330 or 332 in FIG. 3).

As shown in the exemplary embodiment of FIG. 3, tension regulator 350may be coupled to one or more actuation elements of force transmissionmechanism 310 and be configured to passively compensate for slack in theone or more actuation elements. In various exemplary embodiments,tension regulator 350 may be uncoupled to chassis 320 of forcetransmission mechanism 310 and thus may translate freely with anactuation element.

Because of the way in which tension regulator 350 is coupled to anactuation element (e.g., one of actuation elements 340, 342, 344, 346),as the actuation element is wound upon or paid out from a respectiveactuation input mechanism (e.g., actuation input mechanism 330 or 332),such as along the directions indicated by arrows 370 in the exemplaryembodiment of FIG. 3, tension regulator 350 also moves along thedirections indicated by arrows 370 relative to chassis 320. Oneconsideration for such a configuration in which tension regulator 350 iscoupled to an actuation element is that as the actuation element movesback and forth between an actuation input mechanism and aperture 324,tension regulator 350 could impact the actuation input mechanism, ortension regulator 350 could impact chassis portion 322 defining aperture324. Due to the size of force transmission mechanism 310 and thedistance an actuation element travels between aperture 324 and anactuation input mechanism, a small space is provided for a tensionregulator 350 to travel when coupled to an actuation element. In view ofthis, a tension regulator 350 configured to be coupled to an actuationelement may be designed to compensate for slack of the actuation elementbut also have a size small enough to minimize or eliminate impactsbetween the tension regulator 350 and chassis portion 322 or anactuation input mechanism.

In various exemplary embodiments, a tension regulator may be coupled toonly one of the actuation elements connected to an actuation inputmechanism (e.g., when actuation elements 340, 342 in FIG. 3 are definedby two actuation elements) or coupled to only one portion of a singleactuation element that extends between a force transmission mechanismand a distal portion of an instrument (e.g., when actuation elements340, 342 in FIG. 3 are portions of a single actuation element). However,the various exemplary embodiments described herein are not limited tosuch configurations and may instead have tension regulators coupled tomore than one actuation element of a given actuation input mechanism.According to an exemplary embodiment, a tension regulator may be coupledto each actuation element for an actuation input mechanism. Coupling oftension regulators to actuation elements may be based upon, for example,a function of a component being actuated by the actuation elements,according to an exemplary embodiment.

As shown in the exemplary embodiment of FIG. 4, which is a partial viewof actuation elements 340, 342, 344, 346 of the exemplary embodiment ofFIG. 3, a tension regulator 350 may be coupled to actuation element 340but not to actuation element 342. Similarly, a tension regulator 350 iscoupled to actuation element 344. In other words, actuation elements 342and 346 may lack tension regulators 350, as shown in FIGS. 3 and 4.

In a situation where slack is present in both paired actuation elements(e.g., actuation elements 340 and 342 or actuation elements 344 and346), precise control of end effector elements can be improved byselectively accumulating the entire slack onto only one actuationelement of a pair of actuation elements. For example, all slack may beaccumulated with a single tension regulator 350 coupled to one ofactuation elements 340 and 342 or to one of actuation elements 344 and346. Thus, all slack in paired actuation elements 340, 342 or in pairedactuation elements 344, 346 accumulates in a tension regulator 350coupled to one of the actuation elements (e.g., one of actuationelements 340, 342) of the respective pairing, while the other actuationelement of the pairing (e.g., the other of actuation elements 340, 342)is drawn taut due to the removal of slack from the pair of actuationelements via the tension regulator 350. Because the other actuationelement is taught and substantially straight, the length of the otheractuation element is substantially known, which facilitates precisecontrol of an element actuated by the actuation element.

By way of example, when tension regulator 350 is coupled to actuationelement 340 and not to actuation element 342, the tension regulator 350accumulates all slack of the paired actuation elements 340 and 342. Inthis way, actuation element 342 becomes taught, as indicated in FIG. 4,and the length of actuation element 342 is substantially known.Actuation input mechanism 330 may be rotated (e.g., along directions330) by an amount corresponding to the length of actuation element 342in order to precisely control an end effector element actuated byactuation element 342. Conversely, when the length of actuation element342 is not substantially known, such as due to slack in actuationelement 342, rotation of actuation input mechanism 330 does notnecessarily provide precise control of an end effector element becausethe rotation of actuation input mechanism 330 is no longer matched tothe length of actuation element. In other words, an amount of rotationof actuation input mechanism 330 no longer corresponds to a particularamount of paying out or winding up of actuation element 342 becauseslack is present in actuation element 342.

According to various exemplary embodiments, a tension regulator 350 maybe selectively coupled to an actuation element depending upon a functionof the actuation element. Coupling a tension regulator 350 to anactuation element (e.g., actuation element 340) may result in theremoval of slack between a pair of actuation elements (e.g., actuationelements 340, 342) and cause an actuation element of the pair that isnot coupled to a tension regulator (e.g., actuation element 342) tobecome taut and straight, as indicated in FIG. 4, while the otheractuation element to which the tension regulator 350 is coupled (e.g.,actuation element 340), is no longer straight in view of the function ofthe tension regulator 350 accumulating the slack. Because one actuationelement (e.g., actuation element 342) is taut, its length issubstantially known, which facilitates precise functioning of theactuation element, such as to operate an end effector by moving theactuation element an amount corresponding to its length. Conversely, theother actuation element (e.g., actuation element 340) is not straightand therefore it may be more difficult to use the other actuationelement in a precise manner because of its length not being preciselyknown. In view of these considerations, one may select which actuationelement, of a pair of actuation elements, to couple a tension regulatorto based upon the function of the actuation element and how muchprecision is desirable when using the function of the actuation element.

For example, tension regulators 350 in FIGS. 3 and 4 may be coupled toactuation elements 340 and 344 that are pulled to actuate an endeffector (e.g., end effector 220 in FIG. 2) to an open position, whilenot being coupled to actuation elements 342, 346 that are pulled toactuate the end effector to a closed position. Greater precision may bedesirable, for example, for closing an end effector than opening the endeffector, with coupling of the tension regulators 350 being selected inview of this consideration. In such an arrangement, slack is minimizedor eliminated by coupling tension regulators 350 to actuation elements340 and 344 because actuating the end effector to an open position maybe accomplished with less precision and force than actuating the endeffector to a closed position. Conversely, actuation elements 342 and346 may lack tension regulators 350 but are taut due to the removal ofslack via the tension regulators 350 coupled to actuation elements 340,344. Thus, the end effector may be effectively closed in an accuratemanner with a desired amount of force by tensioning actuation elements342, 346.

According to another exemplary embodiment, a tension regulator may becoupled to each actuation element for an actuation input mechanism, asdepicted in the exemplary embodiment of FIG. 5. FIG. 5 is a partial viewof actuation elements 440 and 442 connected to a single actuation inputmechanism (not shown), such as actuation input mechanism 330 or 332 inthe exemplary embodiment of FIG. 3. A tension regulator 450 is coupledto each of actuation elements 440 and 442, as shown in FIG. 5.

As shown in the exemplary embodiments of FIGS. 3-5, a single tensionregulator may be coupled to an actuation element. However, the variousexemplary embodiments described herein are not limited to a singleactuation element being coupled to a particular actuation element.According to an exemplary embodiment, more than one tension regulatormay be coupled to a particular actuation element. For example, two,three, or more tension regulators may be coupled to a particularactuation element.

Turning to FIG. 6, an exemplary embodiment of a tension regulator 550 isshown. Tension regulator 550 may be coupled to an actuation element,such as, for example, any of actuation elements 340, 342, 344, 346 ofthe exemplary embodiment of FIG. 3. Tension regulator 550 may be madeof, for example, stainless steel or other surgical instrument materialsfamiliar to one of ordinary skill in the art. Tension regulator 550 maycomprise a first leg 552 and a second leg 554 connected by a main loop551. First leg 552 may be configured to move (e.g., in a rotationalmanner) relative to main loop 551, such as about the directionsindicated by arrows 557 in the exemplary embodiment of FIG. 6. Secondleg 554 also may be configured to move (e.g., in a rotational manner)relative to main loop 551, such as about the directions indicated byarrows 559 in the exemplary embodiment of FIG. 6. According to anexemplary embodiment, movement of legs 552, 554 may be accomplished via,for example, elastic deformation of tension regulator 550.

Tension regulator 550 may further comprise end loops 553, 555 at eachend of first and second legs 552, 554, as shown in FIG. 6. Loops 551,553, 555 may function to couple tension regulator 550 to an actuationelement. For example, an actuation element (not shown) may pass througheach of loops 551, 553, 555 so tension regulator 550 is coupled to theactuation element. The loop configuration and illustrated in FIGS. 6-10is intended to be exemplary and illustrative only, and it should beappreciated that various modifications can be made without departingfrom the scope of the present disclosure and claims. For example, thedirection (helical direction), pitch, and/or diameter may be modified,for example, to minimize any localized stress risers in the actuationelement. The loop structures in the tension regulator of FIGS. 6-10 alsomay enable the tension regulator to be coupled to an actuation elementalready installed in a force transmission mechanism for an instrument.

The rotation of the legs 552 and 554 about the main loop 551 transitionsthe tension regulator 550 between a configuration in which the tensionregulator is approximately straight and a configuration in which thetension regulator is bent with a reduced angle (e.g., one or more acuteangles or curves in the tension regulator) between the legs 552 and 554,according to an exemplary embodiment. According to an exemplaryembodiment, bending of legs 552, 554, such as relative to main loop 551,may be accomplished via elastic deformation of tension regulator 550.For example, the material from which the tension regulator 550 is madepermits an elastic deformation of the tension regulator between theapproximately straight and bent configurations, with the bentconfiguration being the state into which the tension regulator is biased(e.g., the low energy state of the tension regulator). That is, absent aforce acting in a manner to straighten the tension regulator 550, thetension regulator 550 is naturally in the bent configuration depicted inFIG. 6. According to an exemplary embodiment, tension regulator 550 mayhave a configuration intermediate the approximately straightconfiguration and the bent configuration depicted in FIG. 6, dependingupon the amount of force applied to tension regulator 550 by anactuation element the tension regulator 550 is coupled to.

According to an exemplary embodiment, tension regulator 550 may beconfigured to divert an actuation element from a substantially straightpath along a portion of its length as tension regulator 550 transitionsfrom the approximately straight configuration, such as when theactuation element lacks slack, to the bent configuration of FIG. 6 asthe actuation element develops slack. Tension regulator 550 maytransition from the approximately straight configuration to the bentconfiguration via elastic deformation, which results in a dynamic changein the energy state of the tension regulator 550 (e.g., from a highenergy state in its approximately straight configuration to a lowerstate in the bent configuration). Thus, tension regulator 550 maypassively compensate for an increase in slack in actuation element.

Use and operation of tension regulator 550 will now be described withregard to FIGS. 8-10, according to an exemplary embodiment. FIG. 8depicts tension regulator 550, as described above with regard to FIGS. 6and 7, coupled to an actuation element 560. In particular, actuationelement 560 may be routed through loops 551, 553, 555 of tensionregulator 550 so tension regulator 550 is fastened to actuation element560. As a result, a portion of actuation element 560 may extend throughtension regulator 550 in a continuous, uninterrupted manner. In otherwords, there is no need to attach tension regulator 550 to an end ofactuation element 560, or to attach tension regulator 550 to separateends of actuation element (e.g., with the tension regulator connectingthe separate ends of the actuation element). Further, if actuationelement 560 is pulled along the directions indicated by arrows 570 inFIG. 8, tension regulator 550 moves with actuation element 560, asdescribed above with regard to the exemplary embodiment of FIG. 3. Whena large amount of motion of actuation element 560 occurs, such thatloops 553 or 555 encounter chassis portion 327 or capstan 330 of FIG. 3,for example, tension regulator 550 may slidingly adjust to a newposition on actuation element 560 rather than limit travel of actuationelement 560. In some embodiments, tension regulators may thus berelatively simply coupled to an actuation element already in anassembled state with the force transmission housing components byconfiguring tension members to be able to attach along a continuouslength of the actuation element, as further described with respect tosome exemplary embodiments below.

In the exemplary embodiment of FIG. 8, actuation element 560 is taut,substantially straight, and essentially lacks slack (e.g., prior todeveloping slack). Due to its coupling with tension regulator 550,actuation element 560 applies a force to tension regulator 550, such asby extending actuation element 560 through loops 551, 553, 555. Thiscauses first leg 552 and second leg 554 be pulled away from each other(e.g., via elastically deformation) in directions 557 and 559, such asrelative to main loop 551. As a result, tension regulator 550 has anincreased amount of potential energy due to its substantiallystraightened, elongated configuration shown in FIG. 8, relative to whentension regulator 550 is not bent by actuation element 560. Becauseactuation element 560 extends through end loops 553, 555 and also mainloop 551, and because actuation element 560 is taut and lacks slack inthe exemplary embodiment of FIG. 8, actuation element 560 pulls legs552, 554 and also pulls main loop 551, such as along direction 574relative to a straight axis 571 of actuation element 560 when actuationelement is in the state shown in FIG. 8. According to an exemplaryembodiment, axis 571 may represent a path actuation element 560 followswhen actuation element 560 is taut, substantially straight, andessentially lacks slack (e.g., prior to developing slack), as depictedin FIG. 8.

Over time, actuation element 560 may develop slack, such as, forexample, due to deformation and elongation of actuation element 560.However, tension regulator 550 may compensate for the slack as the slackdevelops in actuation element 560. Turning to FIG. 9, tension regulator550 and actuation element 560 are shown in state in which actuationelement 560 has developed slack relative to the initial non-slack stateshown in FIG. 8. As slack develops, actuation element 560 becomes lesstaut and applies less force to tension regulator 550. This results intension regulator 550 relaxing to a degree and becoming less elasticallydeformed relative to the state shown in FIG. 8. For example, first leg552 may bend relative to main loop 551 in the direction indicated byarrow 557 in FIG. 9 and second leg 554 may bend relative to main loop551 in the direction indicated by arrow 559 in FIG. 9. First leg 552 andsecond leg 554 may bend until the slack has been removed and actuationelement 560 is once again taut, as shown in FIG. 9.

According to an exemplary embodiment, tension regulator 550 may pullactuation element 560 along a direction indicated by arrows 572 in FIG.9, which is substantially perpendicular to the axis 571 of actuationelement 560 as the actuation element 560 develops slack. For example,main loop 551 may move along direction 572 in FIG. 9 and pull actuationelement 560 locally relative to the axis 571 of actuation element 560when actuation element is taut and substantially straight, as depictedin FIG. 8. As a result, some of the potential energy due to thedeformation of tension regulator 550 (e.g., when the actuation element560 is in a taut state and acting on the tension regulator 550) may beused to compensate for, and remove, slack from actuation element 560 soactuation element 560 may remain substantially taut and be used toactuate a surgical instrument. Thus, tension regulator 550 maycompensate for slack in actuation element 560 via a dynamic change inthe potential energy of tension regulator 550.

As shown in the exemplary embodiment of FIG. 8, actuation element 560may be substantially straight when actuation element lacks slack. Forexample, actuation element 560 may extend along a substantially straightpath when actuation element 560 is taut and substantially straight, suchas along axis 571 depicted in FIG. 8. As actuation element 560 developsslack, tension regulator 550 may compensate for the slack by divertingactuation element 560 from the straight path along axis 571. As shown inFIG. 9, the portion of actuation element 560 extending through tensionregulator 550 follows a path that diverges from the path extending along(e.g., is substantially coaxial to) longitudinal axis 571. For example,when actuation element 560 has developed slack, the portion of actuationelement 560 extending through tension regulator 550 may follow a paththrough tension regulator 550 that has a non-zero angle 575 relative toaxis 571, as shown in the exemplary embodiment of FIG. 9. Angle 575,which may depend upon the amount of tension of actuation element 560,may vary between, for example, about 5 degrees to about 80 degrees whenactuation element 560 develops slack. According to another exemplaryembodiment, tension regulator 550 may divert actuation element 560 alonga path having an angle 575 of, for example, about 5 degrees to about 30degrees when actuation element 560 develops slack.

According to an exemplary embodiment, if actuation element 560 developsslack, such as due to elongation of another actuation element thatactuation element 560 is paired with or via an increase in the length ofactuation element 560, such as via stretching of actuation element 560along axis 571, tension regulator 550 may accommodate the slack inactuation element 560 by increasing the path length of the actuationelement 560 in a direction differing from the path along (e.g.,substantially coaxial to) axis 571 of actuation element 560 whenactuation element 560 is taut and substantially straight, as depicted inFIG. 8. For example, tension regulator 550 may accommodate an increasein length of actuation element 560 by pulling actuation element along adirection 572 that is substantially transverse (e.g., perpendicular) tothe longitudinal axis 571 of actuation element 560. As a result, theportion of actuation element 560 extending through tension regulator 550may follow a path having an angle 575 relative to axis 571 of actuationelement 560 when actuation element 560 is taut and substantiallystraight, as depicted in FIG. 8.

Tension regulator 550 may be configured to compensate for varyingamounts of slack in actuation element 560. For example, the slack inactuation element 560 may further increase from the state shown in FIG.9 to the exemplary embodiment shown in FIG. 10. As a result, tensionregulator 550 may relax further and become less elastically deformedrelative to the state shown in FIG. 9, so a change in potential energyof tension regulator 550 due to its deformation may be used todynamically compensate for, and remove, the slack from actuation element560. For example, first leg 552 and second leg 554 may further bendalong their respective directions with regard to main loop 551, withmain loop 551 moving further along direction 572 with regard to axis571. Thus, tension regulator 550 may pull actuation element 560 furtheralong direction 572 and angle 575 for the path of the portion ofactuation element 560 extending through tension regulator 550 mayincrease as the amount of slack increases. As a result, even as theslack of actuation element 560 increases, tension regulator 550 maycontinue to compensate for the slack and keep actuation element 560substantially taut.

Tension regulators of the exemplary embodiments described herein mayhave a maximum slack compensation amount. According to an exemplaryembodiment, the maximum slack compensation amount may correspond to theamount of elastic deformation a tension regulator may undergo. Forinstance, tension regulator 550 may elastically deform an amountcorresponding to the difference between the non-deformed state shown inFIG. 6 and the deformed shape shown in FIG. 8, according to an exemplaryembodiment. The amount of elastic deformation a tension regulator mayundergo may be determined, at least in part, by the material of atension regulator and geometry of a tension regulator, according to anexemplary embodiment. Further, tension regulators of the exemplaryembodiments described herein may be designed to apply a tension to anactuation element, such as in the states shown in the exemplaryembodiments of FIGS. 9 and 10, to remove slack but not apply anexcessive amount of tension, which could overstress an actuationelement.

Other configurations may be used for the tension regulators of theexemplary embodiments described herein. Turning to FIG. 11, a tensionregulator 600 is shown coupled to an actuation element 620. Tensionregulator 600 may be fastened to actuation element 620 so that tensionregulator 600 moves with actuation element 620, as described above withregard to the exemplary embodiment of FIG. 3. FIG. 11 depicts tensionregulator 600 in a non-deformed state. Tension regulator 600 may be madeof, for example, stainless steel or other surgical instrument materialsfamiliar to one of ordinary skill in the art. According to an exemplaryembodiment, apex 606 may be shaped to resist actuation element 620slipping off of apex 606. For example, apex 606 may include projections608 on lateral sides of actuation element 620, as shown in the exemplaryembodiment of FIG. 11.

Tension regulator 600 may be coupled to actuation element 620 bythreading actuation element 620 through holes 610 and 612 in a first leg602, over an apex 606, and through holes 614 and 616 in a second leg 604of tension regulator 600. Thus, when actuation element 620 is taut,substantially straight, and lacks slack, first leg 602 and second leg604 may be bent (e.g., elastically deformed) along respective directions601 and 603 relative to apex 606 and apex 606 may be pulled alongdirection 605 relative to a longitudinal axis 624 of actuation element620, as shown in the exemplary embodiment of FIG. 11. As a result, thepotential energy of tension regulator 600 may be increased and used todynamically compensate for slack that develops in actuation element 620.When actuation element 620 is taut and lacks slack, actuation element620 may be substantially straight and follow a path extending along(e.g., substantially coaxial with) axis 624, as discussed above withregard to the exemplary embodiment of FIG. 8. As actuation element 620develops slack, tension regulator 600 may divert actuation element 620from the path along axis 624. For example, tension regulator 600 maydivert the portion of actuation element 620 extending through tensionregulator 600 along a path forming a non-zero angle 630 relative to axis624. Thus, tension regulator 600 may accommodate slack in actuationelement 620 by increasing the path length of actuation element 620. Inanother example, tension regulator 600 may pull actuation element 620along a direction that is substantially transverse (e.g., perpendicular)to longitudinal axis 624.

Another exemplary embodiment of a tension regulator 700 is shown in FIG.12. Tension regulator 700 may comprise a first leg 702 and a second leg704, with contact portions 720, 722 at respective ends of first andsecond legs 702, 704. Tension regulator 700 may further comprise a mainleg 706 including a contact portion 724. An actuation element (notshown) may be threaded, for example, over contact portions 720, 722 atends of legs 702, 704 and under contact portion 724. According to anexemplary embodiment, first and second legs 702, 704 may be configuredto bend (e.g., elastically deform) relative to main leg 706. Forexample, first and second legs 702, 704 may include an area of materialweakness, such as cutouts 708 and 710, to facilitate first and secondlegs 702, 704 bending relative to main leg 706, such as along directions730 and 732 in the exemplary embodiment of FIG. 12. Thus, tensionregulator 700 may experience a change in potential energy as tensionregulator 700 is bent, which may be used to dynamically compensate forslack in an actuation element.

According to an exemplary embodiment, when an actuation element to whichtension regulator 700 is coupled lacks slack (e.g., is taut andsubstantially straight along a path extending along axis 734 in FIG.12), the actuation element may cause legs 702, 704 to bend alongdirections 730, 732 towards main leg 706. As the actuation elementdevelops slack, tension regulator 700 may relax and legs 702, 704 maybend away from main leg 706. For example, tension regulator 700 mayaccommodate slack in an actuation element by diverting a path ofactuation element from the path along axis 734, similar to the exemplaryembodiments of FIGS. 8-10. As a result, tension regulator 700 mayincrease a path length of the actuation element relative to itslongitudinal axis 734.

Turning to FIG. 13, another exemplary embodiment of a tension regulator810 is depicted. Tension regulator 810 is coupled to an actuationelement 800, such as by joining a first end 812 and a second end 814 oftension regulator 810 to actuation element 800. Tension regulator 810may be a band of elastic material, according to an exemplary embodiment.FIG. 13 depicts a state in which actuation element 800 is taut and lacksslack. As a result, tension regulator 810 is elastically deformed andstretched along actuation element 800, as shown in the exemplaryembodiment of FIG. 13. As actuation element 800 develops slack, asdepicted in the exemplary embodiment of FIG. 14, tension regulator 810may relax along the directions indicated by arrows 820 in FIG. 14 tocompensate for the slack and keep actuation element 800 taut. Similar tothe exemplary embodiments of FIGS. 6-10, tension regulator 810 mayaccommodate slack in actuation element 800 by diverting a path ofactuation element 800 relative to an axis 830 that actuation element 800extends along when actuation element 800 is taut and substantiallystraight, as depicted in FIG. 13. For example, tension regulator 810 mayincrease a length of the path of actuation element 800 relative to axis830.

As described above with regard to the exemplary embodiment of FIG. 3, atension regulator may be fastened to an actuation element so the tensionregulator moves with the actuation element as the actuation element ispaid out or wound upon an actuation input mechanism. According to anexemplary embodiment, contact surfaces of a tension regulator may beconfigured so that the tension regulator is fastened to the actuationelement but if the tension regulator contacts a component of a forcetransmission mechanism (e.g., chassis portion 322 or actuation inputmechanism 330, 332 in FIG. 3) as the actuation element is paid out orwound, the actuation element may be permitted to slide relative to thetension regulator to minimize or prevent damage to the tension regulatorand force transmission mechanism components. For example, surfaces ofloops 551, 553, 555 of tension regulator 550 in the exemplary embodimentof FIG. 6 may be smooth to permit an actuation element to slide relativeto tension regulator 550 when tension regulator 550 impacts a forcetransmission mechanism component. Surfaces of tension regulators 600,700, 800 of the exemplary embodiments of FIGS. 11-14 may also permit anactuation element to slide. According to an exemplary embodiment,surfaces of tension regulators may be shaped to minimize wear of anactuation element due to sliding against a tension regulator, such as byshaping tension regulator surfaces have large radii of curvature.

Turning to FIG. 15, an exemplary embodiment of a tension regulator 900is shown that includes surfaces that couple tension regulator 900 to anactuation element 910 but permit tension regulator 900 to slide relativeto actuation element 910, such as when tension regulator 900 impacts acomponent of a force transmission mechanism. Tension regulator 900 maycomprise a first leg 902 and a second leg 904 connected to a main pulley903, with pulleys 901 and 905 disposed at ends of first and second legs902, 904. First and second legs 902, 904 may bend (e.g., elasticallydeform) relative to main pulley 903, similar to the exemplaryembodiments of FIGS. 6-11. Actuation element 910 may be threaded throughpulleys 901, 903, 905 so that tension regulator 900 is coupled toactuation element 910 but when tension regulator 900 impacts a forcetransmission mechanism component (e.g., chassis portion 322 or actuationinput mechanism 330, 332 of FIG. 3), tension regulator 900 is permittedto slide relative to actuation element 910. According to an exemplaryembodiment, as actuation element 910 develops slack, tension regulator900 may divert a path of actuation element 910 relative to an axis 920of actuation element 910 (e.g., a path along which actuation element 910extends when actuation element 910 is taut and substantially straight),similar to the exemplary embodiments of FIGS. 6-10. As a result, tensionregulator 900 may increase a path length of actuation element 910relative to axis 920, according to an exemplary embodiment.

As discussed above with regard to the exemplary embodiments of FIGS.4-15, a tension regulator may be coupled to a single actuation element.However, the tension regulators of the various exemplary embodimentsdescribed herein are not limited to being coupled to a single actuationelement. Turning to FIG. 16, a tension regulator 1000 is shown coupledto a first actuation element 1010 and a second actuation element 1012.Actuation elements 1010, 1012 may be coupled to the same actuation inputmechanism (e.g., actuation input mechanism 330 or 332 in the exemplaryembodiment of FIG. 3). Tension regulator 1000 may comprise a first end1002 coupled to actuation element 1012 and a second end 1004 coupled toactuation element 1010, with ends 1002, 1004 configured to sliderelative to actuation elements 1010, 1012 as actuation elements 1010,1012 are moved along the directions indicated by arrows 1020 in theexemplary embodiment of FIG. 16. Tension regulator 1000 may comprise adeformable portion 1006 to facilitate deformation (e.g., elasticdeformation) of tension regulator 1000 along the directions indicated byarrows 1022 in FIG. 16, which facilitates compensation for slack in oneor both of actuation elements 1010, 1012. Deformation portion 1006 maybe, for example, a compliant portion of tension regulator 1000 that ismore readily deformable that the remainder of tension regulator 1000,may be formed as a spring, or may have other configurations tofacilitate elastic deformation of tension regulator 1000.

According to an exemplary embodiment, when actuation elements 1010, 1012are taut and lack slack (e.g., prior to developing slack), actuationelements 1010, 1012 may extend along a path along axes 1030, 1032. Insuch a state, deformation portion 1006 is stretched (e.g., via elasticdeformation) tension regulator 1000 experiences an increase in potentialenergy. As actuation elements 1010, 1012 develop slack, deformationportion 1006 may relax and tension regulator 1000 may divert actuationelements 1010, 1012 from a path along (e.g., substantially coaxial to)their respective axes 1030, 1032, similar to the exemplary embodimentsof FIGS. 8-10, to compensate for the slack. For example, portions ofactuation elements 1010, 1012 extending through ends 1002, 1004 may formnon-zero angles with the axes 1030, 1032.

As discussed above with regard to the exemplary embodiments of FIGS.3-16, a tension regulator may be coupled to an actuation element so thatthe tension regulator moves with the actuation element. Thus, thetension regulator moves relative to the chassis of a force transmissionmechanism when the actuation element is paid out and wound upon anactuation input mechanism. The various exemplary embodiments describedherein are not limited to such tension regulators and may also includetension regulators fixed to the chassis of a force transmissionmechanism.

Turning to FIG. 17, an exemplary embodiment of a tension regulator 1100is shown that is fixed to a portion 1106 (e.g., chassis 320 in FIG. 3)of a force transmission mechanism. Tension regulator 1100 may be coupledto an actuation element 1110, such as by extending actuation element1110 through a pulley 1102 or other member of tension regulator 1100that couples tension regulator 1100 to actuation element 1110. Tensionregulator 1100 may further comprise a deformable portion 1104 tofacilitate deformation of tension regulator 1100 along the directionsindicated by arrows 1120 in FIG. 17, which facilitates compensation forslack in actuation element 1110. Deformation portion 1104 may be, forexample, a compliant portion of tension regulator 1100 that is morereadily deformable that the remainder of tension regulator 1100, may beformed as a spring, or may have other configurations to facilitateelastic deformation of tension regulator 1100. When actuation element1110 lacks slack, actuation element 1110 may follow a path along (e.g.,substantially coaxial to) the axis 1130 of actuation element 1110, asdiscussed above with regard to the exemplary embodiments of FIGS. 8-10.As actuation element 1110 develops slack, tension regulator 1100 maypull actuation element 1110, such as along a direction transverse (e.g.,perpendicular to axis 1130). Thus, the path of actuation element 1110differs from the path along axis 1130 when actuation element 1110 istaut and has not developed slack, similar to the exemplary embodiment ofFIGS. 8-10. As a result, tension regulator 1100 may increase a pathlength of actuation element 1110 as slack is developed in actuationelement 1110.

A tension regulator may have a single piece (e.g., monolithic)construction. A tension regulator having a single piece (e.g.,monolithic) construction may be efficient to manufacture and couple toan actuation element but also effective for slack compensation. As shownin the exemplary embodiment of FIGS. 6 and 7, Tension regulator 550 mayhave a single piece (e.g., monolithic) construction. For example,tension regulator 550 may be, for example, a single piece of wire.Tension regulator 600 of the exemplary embodiment of FIG. 11 may alsohave a single piece (e.g., monolithic) construction. For example,tension regulator 600 may be a single piece of sheet metal having theshape shown in the exemplary embodiment of FIG. 11. Another exemplaryembodiment of a tension regulator that may have a single piece (e.g.,monolithic) construction is tension regulator 700 of FIG. 12. Tensionregulator 700 may be molded as a single piece, for example. Tensionregulator 810 of the exemplary embodiment of FIGS. 13 and 14 may alsohave a single piece (e.g., monolithic) construction. According to anexemplary embodiment, tension regulator 1000 of FIG. 16 may have asingle piece (e.g., monolithic) construction that comprises ends 1002,1004 and deformation portion 1006.

Although tension regulators of the various exemplary embodimentscontemplated herein have been described with reference to actuationelements within a force transmission mechanism of a surgical instrument,tension regulators of the various exemplary embodiments described hereinare not limited to use with a force transmission mechanism of aninstrument. For example, tension regulators of the various exemplaryembodiments described herein may be coupled to actuation elements of apatient side cart of teleoperated surgical system. According to anexemplary embodiment, tension regulators of the various exemplaryembodiments described herein may be coupled to actuation elements (e.g.,tension elements) used to actuate manipulator arms 110-113 of patientside cart 100 of the exemplary embodiment of FIG. 1. Thus, tensionregulators of the various exemplary embodiments described herein may becoupled to actuation elements within manipulator arms 110-113, not onlyto actuation elements located within force transmission mechanism 134 ofFIG. 1.

By providing a force transmission mechanism comprising a tensionregulator, slack of an actuation element may be compensated. Further,the tension regulator may have a simple design that is efficient tomanufacture and couple to an actuation element, while being capable ofcompensating for slack of the actuation element.

Further modifications and alternative embodiments will be apparent tothose of ordinary skill in the art in view of the disclosure herein. Forexample, the systems and the methods may include additional componentsor steps that were omitted from the diagrams and description for clarityof operation. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the present teachings. It isto be understood that the various embodiments shown and described hereinare to be taken as exemplary. Elements and materials, and arrangementsof those elements and materials, may be substituted for thoseillustrated and described herein, parts and processes may be reversed,and certain features of the present teachings may be utilizedindependently, all as would be apparent to one skilled in the art afterhaving the benefit of the description herein. Changes may be made in theelements described herein without departing from the spirit and scope ofthe present teachings and following claims.

It is to be understood that the particular examples and embodiments setforth herein are non-limiting, and modifications to structure,dimensions, materials, and methodologies may be made without departingfrom the scope of the present teachings.

Other embodiments in accordance with the present disclosure will beapparent to those skilled in the art from consideration of thespecification and practice of the invention disclosed herein. It isintended that the specification and examples be considered as exemplaryonly, with the claims being entitled to their full breadth and scope,including equivalents.

What is claimed is:
 1. A device to regulate tension of an actuationelement for actuating movement of a surgical instrument, the devicecomprising: an elastically deformable body configured to be coupled tothe actuation element; wherein the deformable body is configured toelastically deform in response to a state of slack occurring in theactuation element; and wherein, as slack occurs in the actuationelement, the deformable body is configured to divert a path of theactuation element to accommodate the slack so the path of the actuationelement differs from an axis the actuation element follows prior to theactuation element developing slack.
 2. The device of claim 1, whereinthe deformable body extends a length of the path of the actuationelement along a direction forming a nonzero angle with the axis theactuation element follows prior to the actuation element developingslack.
 3. The device of claim 1, wherein, as the slack occurs, thedeformable body pulls the actuation element along a directionsubstantially transverse to the axis the actuation element follows priorto the actuation element developing slack.
 4. The device of claim 1,wherein the deformable body comprises first and second legs connected toa central portion of the deformable body, wherein the first and secondlegs are elastically deformable relative to the central portion.
 5. Thedevice of claim 4, wherein the central portion of the tension regulatorcomprises a loop the actuation element extends through.
 6. The device ofclaim 5, wherein the first and second legs each comprise a loop theactuation extends through.
 7. The device of claim 4, wherein an acuteangle is defined between the first and second legs when the first andsecond legs are in a non-deformed state.
 8. The device of claim 4,wherein the elastically deformable body comprises a single piece ofwire.
 9. The device of claim 1, wherein the elastically deformable bodycomprises a single piece of sheet metal.
 10. The device of claim 1,wherein the elastically deformable body comprises a single molded piece.11. A force transmission mechanism for a teleoperated surgicalinstrument, comprising: a chassis; an actuation input mechanism mountedto the chassis, wherein the actuation input mechanism is configured toreceive forces from an actuation interface assembly of a teleoperatedsurgical system; an actuation element configured to transmit forcesufficient to actuate an end effector of the surgical instrument; and atension regulator coupled to the actuation element to compensate forslack of the actuation element; wherein, as slack occurs in theactuation element, the tension regulator is configured to divert a pathof the actuation element to accommodate the slack so the path of theactuation element differs from an axis the actuation element followsprior to the actuation element developing slack.
 12. The forcetransmission mechanism of claim 11, wherein the tension regulator isfastened to the actuation element so the tension regulator moves withthe actuation element when the actuation element is paid out or woundupon the actuation input mechanism.
 13. The force transmission mechanismof claim 11, wherein a portion of the actuation element extendingthrough the tension regulator extends through the tension regulator in acontinuous manner.
 14. The force transmission mechanism of claim 11,wherein the tension regulator comprises first and second legs connectedto a central portion of the tension regulator, wherein the first andsecond legs are elastically deformable relative to the central portion.15. The force transmission mechanism of claim 11, wherein the tensionregulator has a single piece construction.
 16. The force transmissionmechanism of claim 11, wherein the actuation element comprises twoactuation element portions extending from the actuation input mechanismto an exit aperture of the force transmission mechanism, wherein thetension regulator is coupled to one of the actuation element portions.17. The force transmission mechanism of claim 11, wherein the actuationelement comprises two actuation element portions extending from theactuation input mechanism to an exit aperture of the force transmissionmechanism, wherein a tension regulator is coupled to each of theactuation element portions.
 18. The force transmission mechanism ofclaim 11, wherein the actuation element comprises two actuation elementportions extending from the actuation input mechanism to an exitaperture of the force transmission mechanism, wherein the tensionelement is coupled between the actuation element portions.
 19. A methodof compensating for slack in an actuation element of a surgicalinstrument, the method comprising: coupling a tension regulatorcomprising an elastically deformable body to the actuation element; andcompensating for slack developing in the actuation element by divertinga path of the actuation element so the path of the actuation elementdiffers from an axis the actuation element follows prior to theactuation element developing slack.
 20. The method of claim 19, whereinthe compensating comprises the tension regulator extending a length ofthe path of the actuation element along a direction forming a nonzeroangle with the axis the actuation element follows prior to the actuationelement developing slack.
 21. The method of claim 19, wherein thecompensating comprises the tension regulator pulling the actuationelement along a direction substantially transverse to the axis theactuation element follows prior to the actuation element developingslack.
 22. The method of claim 19, wherein coupling the tensionregulator to the actuation element comprises extending a portion of theactuation element through the tension regulator in a continuous manner.